For my next WIP, I had to go back to last spring/summer, when Hypno scored me a SHIELD HeliCarrier on deep discount. I didn't know exactly what I was going to do with it, but one thing I thought would be cool would be to make a shelf (or two) out of it to display some custom SHIELD-type figures on.
1. I took a look at the HeliCarrier and discovered that there wasn't really going to be a centerline that would make for two easy shelves, and decided to just make one deeper one (Mistake #1?) -- I found a mostly continuous line near the 'tower' that would make for a straight cut, and ran it through the table saw with the grinding blade installed.
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2/3. I then took a piece of tongue and groove scrap, thinking that the laps would suffice for holding the shelf (not even close) and instead ran it through the table saw at a 45 degree angle (Mistake #2) with the regular blade reinstalled. The other half of this became the wall mount.
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4/5. Then, I screwed one of the boards to the deck of the HeliCarrier, after making certain for the 10th time that the angles were going to line up correctly to hold this to the wall, not slide off.
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6/7. I started to assemble all the pieces that I wanted to have on the ship, applied the decals, and threw it all in a box for 8 months.
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8. I found a decent place on the wall behind the FLAGG dio display, and screwed the mount to the studs (completely ignoring the pre-drilled holes - if that's what they were)
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9. I then placed the ship on the mounting rail and ... it immediately began to sag and eventually fell off. Eventually, like in 10 seconds. I wound up drilling another screw through the deck railing, through the top board and into a stud. That seems to be holding.
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10. Not putting any figures on this thing for a couple weeks -- just to make sure it isn't going to take a nose dive onto the deck of the FLAGG.
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The biggest challenges to this project:
1. I probably shouldn't have decided to make the deck so deep -- the plastic that makes up this toy is super flimsy, and by cutting away a lot of the support pieces from the other side, wound up with a flimsy plastic/wood joint, no matter how many screws I used to secure it.
2. The 45 degree angle just isn't severe enough for such a thin board and top-heavy shelf. I don't know if a 70/20 or 60/30 cut would have been better, but 45 just wasn't enough to hold the shelf on. Also, by trying to hide the board behind the deck and not extending it down far enough, I unintentionally provided a pivot point for the deck to tip off from.
3. That final/top screw wasn't a deal breaker, but the protruding screw head does keep the 'tower' from fully seating in the recess -- I'm going to have to take that piece and cut out the section where the screw head is.
Thoughts?